Simulated pile fabric structure



Oct. 15, 19 7 I J. CHATANAY 2,809,909

SIMULATED PILE FABRIC STRUCTURE Filed June 17, 1953 2 Sheets-Sheet 1 J. CHATANAY SIMULATED PILE FABRIC STRUCTURE 2 Sheets-Sheet 2 Filed June 17, 1953 FIG. 7

1210 can/"top of Chant-@122 y Elite States This invention relates to carpets, brushes and similar articles of thetype including a plurality of bundle ele ments or tufts implanted near each other in a. flexible supporting member made of an elastic or plastic material to simulate a pile fabric.

The main object of the invention is to provide a simu-' lated pile fabric structure of this type, the tufts of which are adapted to be implanted manually in apertures provided for this purpose in the flexible supporting member, and to be unilaterally locked in said apertures so that they can be extracted therefrom only by being passed through the supporting member in the direction in which they have been implanted thereinto.

.A simulated pile fabric structure according to the invention offers many advantages: 7

, The manual implantation of the tufts may be effected in half the time required for manufacturing areal pile fabric of the same appearance, i. e. offering the same pile density per unit area of its useful face.

A Wool carpet constituted by asimulated-pile fabric structure according to the invention requires only a quarter of the quantity of wool as a similar real woolen fabric. This is due to the suppression of the usual-knots tent which require an important length of wool yarns merely for securing the plies. Moreover, in the conventional carpets, the piles are necessarily levelled when the fabric is completed which gives rise to a considerable waste of wool, which is not the case with a carpet made according to the invention. Since the wool is the most expensive element in a carpet, the invention thus permits considerably reducing the manufacturing cost.

Furthermore, the implantation of the tufts in the flexible support may be effected also by a non-skilled person. In particular, it is possible to. sell to a customer pre-fabri cated tufts and a flexible support adapted toreceive said tufts, together with a pattern, for home carpetmaking. Finally, when a carpet according to the invention is 10- cally worn or injured, it is possible to renovate the same by a mere substitution of a few fresh tufts for the 'deteri orated ones;

. A more particular object of the invention is to provide a carpet constituted by a simulated pile fabric structure of the type described, wherein the flexible supporting member is c'onstituted by an uppercellular structure, each cell of which is adapted to receive a tuft," anjintermediate partition against which the tufts are locked against upward tearing and a lower cellular. structure intended tolie' on the floor.

,7 Thisarrangement ofiers the additional advantages of improving the elasticity of the carpet. ,du'efltolhe double r absorbing effect ensured, on the one hand, by the tufts and,.on the other hand, by the flexiblesupporting member pressed on the floor through its lowercellular struc tnre, of improving the adhering power of the structure on the floor due to the checked configuration ofsaid lower cellular structure and of insulatingthelowerends of the ice tufts from the floor, which suppresses any risk of wear and deterioration due to moisture, etc. b V

A further object of the invention is to provide a simulated pile fabric structure of the type described, each tuft of which is inserted in a two-member base or annular anchoring element, one member of which ensures the above-mentioned unilateral locking of the tuft afterthe same has been implanted into its aperture in theflexible supporting member and the other member of which yieldably locates the tuft in saidaperture, while being capable of passing therethrough under yielding of said aperture when the tuft is urged with a sufiicient force in the direction in which ithas been implanted. 1

The second above described base member of the tuft holds the same centered in its implantation aperture'and presents, moreover, the advantage of facilitating the manual implantation of the first base member by oifering a rigid bearing surface for the fingers.

Air-holes are preferably provided in the partition of the above-mentioned double cellular structure of the flexible' supporting member between the implantation apertures of the tufts to make the structure lighter, to permit vacuum-cleaning of the dusts imprisoned in the lower cells and to facilitate evaporation of the floor humidity. The tufts of the simulated pile fabric structure according to the invention may be easily prefabricated manually by inserting a suitable numberv of yarns in an appropriate base. However, another object of the invention is to provide a process for manufacturing such tufts on a large scale by embedding the yarns in an injection moulded base or annular anchoring element, the latter being preferably of the above described two-rnember type.

This process essentially consists in compressing the yarns in a moulding chamber, injecting into said chamber a suitable plastic material preferably having a low melting point, so as to avoid burning of the yarns, unmolding and then cutting the tuft.

This process oiiers, in particular, the advantage that the yarns are embedded in the moulded base due to their own swelling power, their insertion in the base thus being obtained Without any friction, which avoids any risk of deterioration of the yarns.

continuous succession along the yarns, one tuft being cut from the continuous yarns While a new tuft is being em-.

bedded in its moulded base. It is thus possible to manufacture the tufts at a high rate and to avoid anywaste of raw material.

Other objects and advantages of the invention will be apparent from the following detailed description, together with the accompanying drawings, submitted for purposes of illustration only and not intended to define the scope of the invention, reference being had for that purpose to the subjoined claims.

- In these drawings:

Fig. l is aperspeCfive view' of a carpet according to the invention, with a part of the tufts implanted.

Fig. Zillustrates a processjfor manufacturing tufts according to the invention.

Figs/3 and 4 are cross-sectional views taken along lines 3-3 and 44 of Fig. 2 respectively.

' Fig. 15 shows the mould of Fig. 2, with its shells. sep

arated. b

Fig. 6 illustrates-a polishing brush according to the invention. Y

Fig. 7 shows a supporting member constituted by a number of square plates bonded together.

Pig. 8 is a detailed View of one of the plates shown in i Fig. 7. 1 r 1 1 Fig. 9 is a cross-sectional view of three apertures of Fig. is a cross-sectional view, taken along line 10-10 of Fig. 8, showing the different steps of the implantation of a tuft.

Fig; 11 shows how a tuft may be removed.'

Fig.12 shows in details a modification of the two-member base of a tuft according to the invention, and

Fig. 13 shows another modification of such a base.

The carpet ll, illustrated in perspective in Fig. l, is constituted, according to the invention, by a plurality of tufts 2 implanted and unilaterally locked in aperturesS of a flexible supporting member 4.

It will be understood that the most various and artistic designs may be easily obtained even by a non-skilled person if the same disposes of a suitable pattern (not shown) which may be constituted, e. g., by a simple sheet of card-board or the like, on which small colour circles are previously painted and which may be affixed under the support so that it sufiices to introduce, into the apertures 3, tufts 2 of suitable colours corresponding to those of the pattern circles visible therethrough.

If apertures 3 are provided sufficiently near each other and, if tufts 2 are sufliciently thick, the carpet 1 will perfectly simulate the aspect of a real pile fabric although its cost will be lower beyond compare.

While tufts 2 may be prepared by any suitable process, and even by a mere manual insertion of a number of yarns in a suitable base, within the scope of my invention, I have illustrated in Figs. 2 to 5, an injection mould which is particularly well adapted to a large scale manufacturing of such tufts. In the example shown, each tuft 2 is embedded in a two-member base or annular anchoring element iii-ll, the functions of which will be described in detail hereunder.

As shown in Fig. 2, yarns 5 which may be, for instance, wool yarns are unwound from a drum (not shown), e. g. manually, into a mould comprising two shells 6 and '7 provided with recesses forming, when the mould is assembled, two frusto-conical chambers 8 and 9, in which two bases it) and 11 will be moulded for each tuft.

The injection of the plastic material is effected through suitable ducts 12. Upon assembling of the mould, the yarns 5 are compressed together, as indicated at 13, into a cylindrical bundle so that, upon moulding of the bases, said yarns are automatically embedded in said bases. After unmoulding, the yarns freely swell so that the section of said yarns, which is imprisoned within bases 12 and 11, is firmly clamped therein. Before each moulding operation, the yarns 5 are separately and successively introduced, through grooves provided in shell 6, into the bottom 13 of said grooves. The other shell 7 of the mould is provided with teeth 15 having cylindrical end notches l4 and adapted to be introduced into grooves 16, with a loose fit upon assembling of the mould to compress the yarns in a cylindrical chamber comprising notches 14 and the bottoms 13 of the grooves. The closing and opening displacements of the mold are guided by means of pins 17 implanted in one of the shells and slidably fitting in cylindrical housings provided, for this purpose, in the other shell, the relative arrangement of the pins and their housings being such that the above-mentioned teeth 15 exactly fit into grooves 16.

Such a mould permits a continuous manufacturing process of the tufts, as follows:

The mould is first opened into the position shown in Fig. 5, to permit engagement of the yarns 5, as described above, into the grooves 16. The mould is then closed, which causes compression of the yarns 5 into a compact cylindrical bundle. There is then injected, through ducts 12, a convenient dose of a plastic material, such as nylon, capable of instantaneous setting. The mould is re-opened, yarns 5 are removed with their moulded bases and the whole assembly is so shifted as to bring base 11 into an indexing recess provided at the left end (Fig. 2) of the mould.

Then, a second moulding operation may be effected on the next length of the yarns, whereupon the whole assembly is further shifted leftwards into the position shown in Fig. 2. It then remains only to cut the length comprised between the dot-dash lines a-a, a'-a, to obtain a first tuft, and so on.

It will be understood that this process offers, in particular, the advantage of suppressing any wastage of yarn. A small yarn length 5a projects under base 16 for a purpose which will be explained hereunder. Moreover, if a plastic material having a low melting point, such as nylon, is used, any risk of burning of the yarns is avoided. Furthermore, since as explained above, the clamping of the yarns in the bases is obtained by the very elasticity of the yarns and plasticity of the bases, any risk of deterioration of the yarns by the outer edges of the bases is avoided.

In Fig. 6 is shown a polishing brush constituted by a simulated pile fabric according to the invention, comprising a plurality of tufts 2 implanted in the apertures of a supporting member 4.

In Fig. 7, is shown a supporting member constituted by a number of square plates bonded on their edges, e. g. by high-frequency welding, said plates being made of a plastic or elastic material, such as synthetic rubber or the like.

After assembling, as shown at 29, 2G of the adjacent edges of the plates, the whole assembly is enclosed in an external ledge 21. Finally, holes 22 are provided to ensure ventilation of the carpet apertures, so as to prevent gathering of dust or dampness under the carpet.

As shown in Fig. 10, each cell or recess of the supporting member is divided into two compartments by a partition 23 which extends at right-angles with the checked walls of the recesses. According to the invention, a frusto-conical aperture, having its smaller end turned downwards, is provided in the partition 23, within each recess, the diameter of the small end of the frusto-conical aperture being smaller than the diameter of the wide end of base 19 and substantially equal to the diameter of the small end of base 11. With this arrangement, as shown in Fig. 11, base 10 is easily introduced downwardly into the frusto-conical aperture under deformation of the edges of said aperture (steps A and B), whereupon, the second base 11 fits in the frusto-conical aperture, as indicated at C.

If, in these conditions, an upward pull is exerted on the tufts, as indicated at D, base 16 is brought into contact with the partition 23, thus locking the tufts against tearing. Moreover, if a heavy body, such as a piece of furniture, is placed on the carpet, as indicated at E, there are three successive absorbing effects, viz., first the crushing of the tufts, then a deformation of the partition 19 and the relevant walls of the recesses and, finally, crushing of the residual length 5a as provided under base it), as mentioned-above.

As shown in Fig. 11, to remove a tuft, it sutfices to exert on the same an axial stress in the direction in which it has been implanted into its aperture, e. g. by means of a pencil or the like, so as to force through the relevant frusto-conical aperture, first the second base 11 and then, the yarns of the tufts.

In Figs. 12 and 13 are shown two alternative constructions of the two-member base of the tufts.

In Fig. 13, base 10 offers a pyramidal shape, which makes the implantation of the tufts easier by limiting the frictions to the corners of the pyramid.

In Fig. 12, the shape of the base is a combination of conical and pyramidal sections that offers the same advantage as the embodiment of Fig. 13, without having the drawback of having too sharp cutting edges.

What I claim is:

1. A simulated pile fabric structure comprising, in combination, a flat flexible supporting member having a plurality of identical apertures therein, a plurality of annular anchoring elements, each of which is forcibly and yieldably engageable through any one of said apertures from one side of said supporting member and each anchoring element having a radial surface adapted to lockingly contact the other side of said supporting member, and a bundle of yarn lengths clamped in each of said anchoring elements to constitute therewith a removable tuft.

2. A simulated pile fabric structure comprising, in combination, a flat flexible cellular supporting member, an intermediate apertured partition in each cell parallel to the flat faces of said member to divide each cell of the same into two compartments, a plurality of annular anchoring elements each of which elements is forcibly and yieldably engageable through an aperture from one side of said partition and each element having a radial surface adapted to lockingly contact the other side of said partition, and a bundle of yarn lengths clamped in each of said anchoring elements to constitute therewith a removable tuft.

3. A simulated pile fabric structure according to claim 1, wherein said apertures and said anchoring elements are frusto-conical, the smallest diameter of said apertures being materially smaller than the wider end of said anchoring elements.

4. A simulated pile fabric structure comprising, in

combination, a flat flexible cellular supporting member, an intermediate apertured partition in each cell parallel to the flat faces of said member to divide each cell of the same into two compartments, said aperture being frustoconical. a plurality of annular anchoring elements each of which elements includes two frusto-conical members, the leading one of said frusto-conical members being forcibly and yieldably engageable through said aperture from the side of said partition on which said aperture has its largest diameter and having the largest diameter of said leading frusto-conical member materially larger than the smallest diameter of said aperture and the other of said frusto-conical members being adapted to fit in said aperture, after said first member has been fully passed therethrough, and a bundle of yarn lengths clamped in each of said anchoring elements to constitute therewith a removal tuft.

5. A simulated pile fabric structure comprising a flat flexible apertured supporting member and a plurality of annular anchoring elements each of which elements comprises two surfaces, the surface closest to the end of the yarn lengths being frusto-conical and of such a size that it is yieldably engageable through an aperture in said supporting member, and a bundle of yarn lengths clamped in each of said anchoring elements to constitute therewith a removal tuft.

References Cited in the file of this patent UNITED STATES PATENTS 2,217,137 Roth et al. Oct. 8, 1940 2,268,049 McGuire Dec. 30, 1941 2,310,186 Abrams Feb. 2, 1943 2,480.004 Dildilian Aug. 23, 1949 2,495,666 Taubert Jan. 24, 1950 2,524,456 M-asland Oct. 3, 1950 2,636,460 Seiderman Apr. 28, 1953 2,713,012 Hartstein July 12, 1955 FOREIGN PATENTS 198,185 Great Britain 1923 

5. A SIMULATED PILE FABRIC STRUCTURE COMPRISING A FLAT FLEXIBLE APERTURED SUPPORTING MEMBER AND A PLURALITY OF ANNULAR ANCHORING ELEMENTS EACH OF WHICH ELEMENTS COMPRISES TWO SURFACES, THE SURFACE CLOSEST TO THE END OF THE YARN LENGTHS BEING FRUSTO-CONICAL AND OF SUCH A SIZE THAT IT IS HIELDABLY ENGAGEABLE THROUGH AN APERTURE IN SAID SUPORTING MEMBER, AND A BUNDLE OF YARN LENGTHS CLAMPED IN EACH OF SAID ANCHORING ELEMENTS TO CONSTITUTE THEREWITH A REMOVAL TUFT. 